Ultrasonic surgical blade for use with ultrasonic surgical instruments

ABSTRACT

A surgical instrument includes an ultrasonic transducer, an ultrasonic transmission waveguide extending from the ultrasonic transducer, and an ultrasonic blade acoustically coupled to the ultrasonic transmission waveguide. The ultrasonic blade includes a base and a curved body extending distally from the base. The curved body includes a tissue-treating surface extending on a first side of the curved body and a curved edge extending on a second side of the curved body opposite the first side. The curved edge has a proximal end and a distal end, wherein the proximal end is offset from the distal end in a first direction, wherein the proximal end is offset from the distal end in a second direction, and wherein the first direction is perpendicular to the second direction.

BACKGROUND

The present disclosure relates to surgical instruments and, in variousembodiments, to ultrasonic surgical instruments.

Ultrasonic surgical instruments are used in many applications insurgical procedures by virtue of their unique performancecharacteristics. In various instances, ultrasonic surgical instrumentscan be configured for use in open, laparoscopic, or endoscopic surgicalprocedures. Ultrasonic surgical instruments can be also configured foruse in robotic-assisted surgical procedures.

FIGURES

The features of the various embodiments are set forth with particularityin the appended claims. The various embodiments, however, both as toorganization and methods of operation, together with advantages thereof,may best be understood by reference to the following description, takenin conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 2 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 3 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 4 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 5 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 6 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 7 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 8 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 9 is a perspective view of an ultrasonic surgical blade accordingto one embodiment;

FIG. 9A is a front view of an ultrasonic surgical blade according to oneembodiment;

FIG. 10 is a sectional view of the ultrasonic surgical blade shown inFIG. 12 taken along section line 10-10, according to one embodiment;

FIG. 11 is a top view of an ultrasonic surgical blade according to oneembodiment;

FIG. 12 is a side view of an ultrasonic surgical blade according to oneembodiment;

FIG. 13 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 13-13, according to one embodiment;

FIG. 14 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 14-14, according to one embodiment;

FIG. 15 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 15-15, according to one embodiment;

FIG. 16 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 16-16, according to one embodiment;

FIG. 17 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 17-17, according to one embodiment;

FIG. 18 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 18-18, according to one embodiment;

FIG. 19 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 19-19, according to one embodiment;

FIG. 20 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 20-20, according to one embodiment;

FIG. 21 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 21-21, according to one embodiment;

FIG. 22 is a sectional view of the ultrasonic surgical blade shown inFIG. 11 taken along section line 22-22, according to one embodiment;

FIG. 23 is a partial side view of an ultrasonic surgical instrumentincluding an end effector assembly according to one embodiment;

FIG. 24 is an exploded view of end effector assembly of the ultrasonicsurgical instrument of FIG. 23 according to one embodiment;

FIG. 25 is a top view of an ultrasonic surgical blade according to oneembodiment;

FIG. 26 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 26-26, according to one embodiment;

FIG. 27 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 27-27, according to one embodiment;

FIG. 28 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 28-28, according to one embodiment;

FIG. 29 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 29-29, according to one embodiment;

FIG. 30 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 30-30, according to one embodiment;

FIG. 31 is a sectional view of the ultrasonic surgical blade shown inFIG. 25 taken along section line 31-31, according to one embodiment; and

FIG. 32 is a side view of an ultrasonic surgical instrument including anend effector assembly and a handle assembly according to one embodiment.

DESCRIPTION

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongated shaft of a surgical instrument can be advanced.

Referring generally to FIGS. 1-9, an ultrasonic blade 10 is depicted invarious perspective views taken at approximately 30° intervals as theblade is rotated in the counterclockwise direction. The ultrasonic blade10 comprises a body 12 that generally protrudes, or extends, from a base13 in a distal direction terminating in a blunt, or at leastsubstantially blunt, tip 14. The body 12 generally includes a first face16 and a second face 18 opposite, or at least substantially opposite,the first face 16. The reader will appreciate that the blunt tip 14 canbe fine but sufficiently atraumatic to allow for improved otomtycreation and separation of tissue planes.

The first face 16 may include a tissue-treating surface 20, a first sidewall 22, and a second side wall 24, as best illustrated in FIG. 2. Thesecond face 18 may include a first tissue-cutting surface 26 and asecond tissue-cutting surface 28 intersecting at a cutting edge 30, asbest illustrated in FIG. 7. A first intermediate wall 32 may extend, atleast partially, between the first side wall 22 and the firsttissue-cutting surface 26, as best illustrated in FIG. 1. A secondintermediate wall 34 may extend, at least partially, between the secondside wall 24 and the second tissue-cutting surface 28, as bestillustrated in FIG. 4.

The side walls 22, 24 extend, or substantially extend, on opposite sidesof the tissue-treating surface 20, as best illustrated in FIG. 2. In oneembodiment, as illustrated in FIG. 2, the tissue-treating surface 20 isbeveled, or shaved, by the side walls 22, 24, which causes thetissue-treating surface 20 to be tapered, or narrowed, to a distal end21 at a position proximal to the blunt tip 14. Said another way, thetissue-treating surface 20 is defined between two contour lines 23, 25that extend proximally from the distal end 21. The first contour line 23extends between the first side wall 22 and the tissue-treating surface20. And, the second contour line 25 extends between the second side wall24 and the tissue-treating surface 20. The contour lines 23, 25 followseparate and generally curved paths that intersect at the distal end 21.

The tissue-treating surface 20 can be flat, or at least substantiallyflat, such that the contour lines 23, 25 may extend, or substantiallyextend, in a single plane. The flatness of the tissue-treating surface20 can facilitate using the tissue-treating surface 20 as a tissuesealing surface for sealing tissue captured against the tissue-treatingsurface 20. A significant advantage of the blade 10 is its ability toseal relatively large blood vessel such as, vessels comprising adiameter in the order of 7 mm, for example, with relatively shorttransection time such as, for example, 8 seconds. The one or both of thecontour lines 23, 25 can be in the form of a sharp edge. Alternatively,one or both of the contour lines 23, 25 can be in the form of shaved toyield a smooth transition from the side walls 22, 24 to thetissue-treating surface 20.

In the remaining distance between the distal end 21 and the blunt tip14, the side walls 22, 24 may directly intersect, or at least partiallyintersect, each other, for example. In other embodiments, the distal end21 can be positioned at the blunt tip 14, or just proximal to the blunttip 14. In at least one embodiment, the distal end 21 can be positionedcloser to the blunt tip 15 than the base 13, as illustrated in FIG. 2.In at least one embodiment, the position of the distal end 21 can beequidistant between the blunt tip 14 and the base 13, for example.

An angle α1 can be defined between contour lines 23, 25, as illustratedin FIG. 2. The angle α1 can be any angle selected from a range of about1° to about 15°, for example. In one example, the angle α1 can be anyangle selected from a range of about 3° to about 10°. In one example,the angle α1 can be about 5°.

Referring to FIG. 10, a longitudinal cross-section of the blade 10 isdepicted. The blade 10, as illustrated in FIG. 10, has a length L1, andincludes a straight, or a substantially straight, portion 36 comprisinga length L2, and a curved, or arcuate, portion 38 comprising a lengthL3. As illustrated in FIG. 10, the length L1 of the blade 10 is measuredfrom the base 13 to the blunt tip 14. In certain instances, the lengthL1 can be any length selected from a range of about 0.4 inch to about1.2 inch. In certain instances, the length L1 can be any length selectedfrom a range of about 0.6 inch to about 0.8 inch. In certain instances,the length L1 can be any length selected from a range of about 0.70 inchto about 0.75 inch. In one instance, the length L1 can be about 0.728inch, for example.

In certain instances, the length L2 can be any length selected from arange of about 0.02 inch to about 0.10 inch. In certain instances, thelength L2 can be any length selected from a range of about 0.03 inch toabout 0.07 inch. In one instance, the length L1 can be about 0.05 inch,for example.

In certain instances, the length L3 can be any length selected from arange of about 0.02 inch to about 0.10 inch. In certain instances, thelength L2 can be any length selected from a range of about 0.03 inch toabout 0.07 inch. In one instance, the length L3 can be about 0.767 inch,for example.

In certain instances, the length L3 can be any length selected from arange of about 0.50 inch to about 1.00 inch. In certain instances, thelength L3 can be any length selected from a range of about 0.60 inch toabout 0.80 inch. In one instance, the length L3 can be about 0.67 inch,for example. Other values for the lengths L1, L2, and/or L3 arecontemplated by the present disclosure.

Referring again to FIG. 10, the blade 10 may comprise a width W1 at thebase 13, a maximum width W2 at an inflection region 44, which is adistance L4 from the proximal end of the base 13, and a minimum width W3at the blunt tip 14. As illustrated in FIG. 10, the width of the blade10 can be tapered gradually along a length of the blade 10 from themaximum width W2 at the inflection region 44 to the minimum width W3 atthe blunt tip 14, for example.

In certain instances, the width W1 can be any width selected from arange of about 0.030 inch to about 0.270 inch. In certain instances, thewidth W1 can be any width selected from a range of about 0.060 inch toabout 0.180 inch. In one instance, the width W1 can be about 0.090 inch,for example.

In certain instances, the width W2 can be any width selected from arange of about 0.030 inch to about 0.270 inch. In certain instances, thewidth W2 can be any width selected from a range of about 0.060 inch toabout 0.180 inch. In one instance, the width W2 can be about 0.090 inch,for example.

In certain instances, the width W3 can be any width selected from arange of about 0.120 inch to about 0.010 inch. In certain instances, thewidth W1 can be any width selected from a range of about 0.080 inch toabout 0.030 inch. In one instance, the width W3 can be about 0.044 inch,for example. Other values for the widths W1, W2, and/or W3 arecontemplated by the present disclosure.

In certain instances, the length L4 can be any length selected from arange of about 0.200 inch to about 0.300 inch. In certain instances, thelength L4 can be any length selected from a range of about 0.250 inch toabout 0.280 inch. In one instance, the length L3 can be about 0.270inch, for example. Other values for the length L4 are contemplated bythe present disclosure.

Referring primarily to FIGS. 9A, 10, Cartesian coordinate system isdefined such that in FIG. 9A, the X-axis of the Cartesian coordinatesystem extends away from the page. And in FIG. 10, the Z-axis extendsaway from the page. In the embodiment illustrated in FIGS. 9A, 10, theX- and Z-axes of the Cartesian coordinate system define an XZ plane thattransects the tissue-treating surface 20. In certain instances, asillustrated in 10, the XZ plane transects the tissue-treating surface 20at an angle of about 90°, for example. In addition, the XZ plane mayextend along a centerline 45 (FIG. 10) that extends through the base 13.

The curved portion 38 of the blade 10 is designed to fit and be passedthrough a tubular channel such as, for example, a trocar (not shown)during use of the blade 10 in a laparoscopic procedure, for example.Accordingly, to maximize the curvature of the blade 10 while stayingwithin a size limit dictated by the diameter of the trocar, for example,the curved portion 38 of the blade 10 follows a unique trajectory withrespect to the XZ plane.

Essentially, the curved portion 38 comprises a substantially arcuateprofile that begins, or substantially begins, on a first side of the XZplane, as illustrated in FIG. 10. The profile of the curved portion 38then crosses the XZ plane to a second side of the XZ plane opposite thefirst side. Then, the profile of the curved portion 38 turns at aninflection region 44, and returns once again to the first side such thatthe blunt tip 14 is completely positioned on the first side of the XZplane, as illustrated in FIG. 10. Accordingly, the profile of the curvedportion 38 extends on both sides the XZ plane.

The cross-sectional area of the curved portion 38, as illustrated inFIG. 10, includes a proximal region 40, an inflection region 44, and adistal region 42. The proximal and distal regions 40, 42 can reside onthe first side of the XZ plane, while the inflection region 44 residesmainly on the second side of the XZ plane.

In one example, more the 50% of the width W2 at the inflection region 44resides on the second side of the XZ plane. In another example, more the60% of the width W2 at the inflection region 44 resides on the secondside of the XZ plane. In another example, more the 70% of the width W2at the inflection region 44 resides on the second side of the XZ plane.In another example, more the 80% of the width W2 at the inflectionregion 44 resides on the second side of the XZ plane. In anotherexample, more the 90% of the width W2 at the inflection region 44resides on the second side of the XZ plane.

In certain instances, the curved portion 38 has a tilted or unevencurved profile. As illustrated in FIG. 10, the proximal and distalregions 40, 42 can reside at different perpendicular distances from theXZ plane. For example, the distal region 42 may be positioned furtheraway from the XZ plane than the proximal region 40. Such a design isadvantageous because it permits that blunt tip 14 of the blade 10 toextend or protrude outward, or to the side, beyond the base 13, whichenhances the visibility of the blunt tip 14 from a position proximal tothe base 13, as illustrated in FIG. 9A.

In the embodiment illustrated in FIG. 10, the distal region 42intersects the centerline 45 at an angle α3 selected from a range ofabout 10° to about 80°, for example. In one embodiment, angle α3 can beany angle selected from a range of about 30° to about 60°, for example.In one embodiment, the angle α3 can be about 40°, for example. Othervalues for the angle α3 are contemplated by the present disclosure.

In one example, the perpendicular distance between the proximal region40 and the XZ plane is about 0.045 inch, while the perpendiculardistance between the distal region 42 and the XZ plane is about 0.075inch. In this example, as illustrated in FIG. 10, the perpendiculardistance between the inflection region 44 and the XZ plane is about0.075 inch.

In certain instances, the perpendicular distance between the proximalregion 40 and the XZ plane is any distance selected from a range ofabout 0.030 inch to about 0.080 inch. In certain instances, theperpendicular distance between the proximal region 40 and the XZ planeis any distance selected from a range of about 0.050 inch to about 0.060inch. In certain instances, the perpendicular distance between thedistal region 42 and the XZ plane is any distance selected from a rangeof about 0.050 inch to about 0.100 inch. In certain instances, theperpendicular distance between the distal region 42 and the XZ plane isany distance selected from a range of about 0.070 inch to about 0.080inch. In certain instances, the perpendicular distance between theinfliction region 44 and the XZ plane is any distance selected from arange of about 0.050 inch to about 0.100 inch. In certain instances, theperpendicular distance between the infliction region 44 and the XZ planeis any distance selected from a range of about 0.070 inch to about 0.080inch. Other values for the distances described above are contemplated bythe present disclosure.

In certain instances, the ratio of the perpendicular distance betweenthe proximal region 40 and the XZ plane to the perpendicular distancebetween the distal region 42 and the XZ plane is any value selected froma range of about one quarter to about three quarters. In certaininstances, the ratio of the perpendicular distance between the proximalregion 40 and the XZ plane to the perpendicular distance between thedistal region 42 and the XZ plane is any value selected from a range ofabout one third to about two thirds.

Like the width of the curved portion 38, the height of the curvedportion 38 can be tapered as well. As illustrated in FIG. 9, the heightof the curved portion 38 can be tapered gradually along a length of theblade 10 from a maximum height H1 at a the proximal end of the curvedportion 38 to a minimum height H2 at the blunt tip 14, for example.

In certain instances, the height H1 can be any height selected from arange of about 0.070 inch to about 0.110 inch. In certain instances, theheight H1 can be any height selected from a range of about 0.070 inch toabout 0.100 inch. In one instance, the height H1 can be about 0.090inch, for example.

In certain instances, the height H2 can be any height selected from arange of about 0.040 inch to about 0.070 inch. In certain instances, theheight H2 can be any height selected from a range of about 0.050 inch toabout 0.060 inch. In one instance, the height H2 can be about 0.054inch, for example.

In certain instances, the ratio of the height H2 to the height H1 isselected from a range of values between about 0.2 to about 0.8. Incertain instances, the ratio of the height H2 to the height H1 isselected from a range of values between about 0.3 to about 0.7. In oneexample, the ratio of the height H2 to the height H1 is about 0.6.

Referring primarily to FIGS. 1, 13, and 14, the base 13 may comprise agenerally cylindrical shape with a flat top region 50 that extendsproximally from the tissue-treating surface 20. As illustrated in FIG.10, the centerline 45 may extend through a central axis of thecylindrical base 13. The curved portion 38 of the blade 10 crosses thecenterline 45 causing the blunt tip 14 to extend, or protrude, laterallybeyond the base 13 to enhance the visibility of the blunt tip 14 from aposition proximal to the base 13, as illustrated in FIG. 14.

The blade 10 may include one or more acoustic balancing features. Theacoustic balancing features are primarily sections of the blade 10 thatare modified to acoustically balance the blade 10. In certain instances,the acoustically balancing features can be sections of the blade 10 thatare removed or shaved to acoustically balance the blade 10.

Referring primarily to FIGS. 1, 15, and 16, a first acoustic balancingfeature 52 is provided on a first side of the blade 10. The firstacoustic balancing feature 52 encompasses a region that extends distallyfrom a distal end of the base 13. In the embodiment illustrated in FIG.1, the first acoustic balancing feature 52 has a first contour line 54that intersects the tissue-treating surface 20, the first side wall 22,and first intermediate wall 32.

As illustrated in FIG. 1, the first contour line 54 of the acousticbalancing feature 52 interrupts the proximal extension of the of thefirst side wall 22 and the first intermediate wall 32 toward the base13. A second contour line 56 of the first acoustic balancing feature 52intersects the first tissue-cutting surface 26, as illustrated inFIG. 1. The contour lines 54 and 56 may intersect at a distal tip 57, asillustrated in FIG. 1.

As best illustrated in FIG. 2, the first contour line 54 of the firstacoustic balancing feature 52 may interrupt the proximal extension ofthe first contour line 23 of the tissue-treating surface 20 therebyreducing or shaving the width of the tissue-treating surface 20 tocreate a narrowed proximal region 27. The interruptions caused by thefirst acoustic balancing feature 52 modify the shape of the blade 10 toimprove its acoustic balance which is crucial to the function of theblade 10.

Referring primarily to FIG. 6, the blade 10 may include a secondacoustic balancing feature 60. As illustrated in FIG. 6, the secondacoustic balancing feature 60 may intersect the second tissue-cuttingsurface 28 at a contour line 62. In the embodiment illustrated in FIG.6, the second acoustic balancing feature 60 comprises a generally curvedshape that terminates at a peak 64.

Referring again to FIG. 6, a third acoustic balancing feature 66 mayintersect the first tissue-cutting surface 26 at a contour line 68. Likethe second acoustic balancing feature 60, the third acoustic balancingfeature 66 may comprises a generally curved shape that terminates at apeak 70. In the embodiment illustrated in FIG. 6, the second acousticbalancing feature 60 comprises a greater radius of curvature that thirdacoustic balancing feature 66. In other embodiments, the third acousticbalancing feature 66 comprises a greater radius of curvature than thesecond acoustic balancing feature 60. In other embodiment the secondacoustic balancing feature 60 and the third acoustic balancing feature66 comprise the same, or at least substantially the same, radius ofcurvature.

Referring primarily to FIG. 7, a fourth acoustic balancing feature 72extends further proximally from the second acoustic balancing feature 60and the third acoustic balancing feature 66. The fourth acousticbalancing feature 72 includes a first contour line 74 which comprises acurved shape and generally extends from the peak 64 to the peak 70, asbest illustrated in FIG. 7. Additionally, the fourth acoustic balancingfeature 72 includes a second contour line 76 that intersects the secondacoustic balancing feature 60, and a third contour line 78 thatintersects the third acoustic balancing feature 66.

In the embodiment illustrated in FIG. 7, the contour lines 76, 78intersect each other at a proximal end 33 of the cutting edge 30.Furthermore, the contour lines 62 and 68 may also intersect each otherat the proximal end of the cutting edge 30, as illustrated in FIG. 7.

In one embodiment, the ultrasonic energy transmitted to tissue pressedagainst the cutting edge 30 can be employed to sever the tissue. In suchembodiment, the blade 10 can be manipulated by an operator to positionthe cutting edge 30 against the tissue. Ultrasonic energy can then betransmitted to the tissue through the cutting edge 30 thereby causingthe tissue to be severed or cut.

As best illustrated in FIG. 7, the first tissue cutting surface 26extends distally from the contour line 68 which defines a distalperimeter of the third acoustic balancing feature 66. In a similarmanner, the second tissue-cutting surface 28 extends distally from thecontour line 62 which defines a distal perimeter of the second acousticbalancing feature 60. In the embodiment illustrated in FIG. 7, thecutting surfaces 26, 28 extend distally in generally curved paths alongside each other defining a generally curved contour line therebetweenthe produces the cutting edge 30.

The reader will appreciate that the angle between the cutting surfaces26, 28 can, at least in part, determine the sharpness of the cuttingedge 30. In certain instances, the angle between the cutting surfaces26, 28 can be the same, or substantially the same, along the length ofthe cutting edge 30. Alternatively, the angle between the cuttingsurfaces 26, 28 can be varied along the length, or at least a portion ofthe length, of the cutting edge 30. Accordingly, the sharpness of thecutting edge 30 can be varied along the length, or at least a portion ofthe length, of the cutting edge 30. In one embodiment, a proximalportion of the cutting edge 30 can be sharper than a distal portion ofthe cutting edge 30. Alternatively, a distal portion of the cutting edge30 can be sharper than a proximal portion of the cutting edge 30.

The angle(s) between the cutting surfaces 26, 28 can be selected from arange of about 10° to about 175°. In one embodiment, the angle(s)between the cutting surfaces 26, 28 can be selected from a range ofabout 80° to about 170°. In one embodiment, the angle(s) between thecutting surfaces 26, 28 can be selected from a range of about 110° toabout 160°. In one embodiment, the angle(s) between the cutting surfaces26, 28 can be selected from a range of about 120° to about 150°. Othervalues for the angle(s) between the cutting surfaces 26, 28 can becontemplated by the present disclosure.

In one embodiment, referring primarily to FIG. 18, an angle α2 betweenthe cutting surfaces 26, 28 at a distal end portion of the firstacoustic balancing feature 52 may be selected from a range of about 85°to about 120°. In one instance, the angle α2 can be about 110°, forexample.

Referring primarily to FIG. 9A, a front view of one embodiment of theblade 10 is illustrated. In the embodiment illustrated in FIG. 9A, theblade 10 is tapered such that the proximal end 33 of the cutting edge 30is further away from a plane defined by the tissue-treating surface 20than the distal end 35 of the cutting edge 30. Said another way, theproximal end 33 of the cutting edge 30 is vertically offset from thedistal end 35 of the cutting edge 30.

Furthermore, the proximal end 33 and the distal end 35 reside onopposite sides of the XZ plane. Said another way, the proximal end 33 ofthe cutting edge 30 can be horizontally offset from the distal end 35 ofthe cutting edge 30. FIGS. 28, 29 illustrate a longitudinalcross-section of the blade 10 taken along the XZ plane. FIG. 28 depictsthe first side of the XZ plane which includes the distal end 35 of thecutting edge 30. FIG. 29 depicts the second side of the XZ plane whichincludes the proximal end 35 of the cutting edge 30.

In various instances, the ultrasonic blade 10 can be incorporated intoan ultrasonic surgical instrument. For example, the ultrasonic blade 10can be incorporated into an ultrasonic surgical instrument that includesa clamp member that may be controlled by an operator of the ultrasonicsurgical instrument to capture tissue between the clamp member theultrasonic blade 10 to treat the captured tissue. Examples of suchultrasonic surgical instruments and their mechanisms of operation aredepicted in U.S. patent application Ser. No. 14/448,430, titledACTUATION MECHANISMS AND LOAD ADJUSTMENT ASSEMBLIES FOR SURGICALINSTRUMENTS, filed Jul. 31, 2014, and U.S. Patent Publication No.2014/0005704 A1, titled ULTRASONIC SURGICAL INSTRUMENTS WITH DISTALLYPOSITIONED JAW ASSEMBLIES, filed Jun. 29, 2012.

FIG. 32 illustrates a right side view of one embodiment of an ultrasonicsurgical instrument 110 suitable for use with the ultrasonic blade 10.In the illustrated embodiment, the ultrasonic surgical instrument 110may be employed in various surgical procedures including endoscopic ortraditional open surgical procedures. In one example embodiment, theultrasonic surgical instrument 110 comprises a handle assembly 112extending proximally from an elongate shaft assembly 114, and an endeffector assembly 126 extending distally from the elongate shaftassembly 114. An ultrasonic transmission waveguide 178 (FIG. 24) mayextend, or at least partially extend, through the elongate shaftassembly 114. A distal end portion of the ultrasonic transmissionwaveguide 178 can be acoustically coupled (e.g., directly or indirectlymechanically coupled) to the blade 10. A proximal end portion of theultrasonic transmission waveguide 178 can be received within the handleassembly 12 for acoustic coupling to an ultrasonic transducer 116.

The handle assembly 112 comprises a trigger 132, a handle 133, a distalrotation assembly 113, and a switch assembly 128. The elongated shaftassembly 114 comprises an end effector assembly 126 and actuatingelements to actuate the end effector assembly 126. The handle assembly112 is adapted to receive the ultrasonic transducer 116 at the proximalend. The ultrasonic transducer 116 can be mechanically engaged to theelongated shaft assembly 114 and portions of the end effector assembly126. The ultrasonic transducer 116 can be electrically coupled to agenerator 120 via a cable 122. In certain instances, the generator 120can be integrated with the handle assembly 112, for example. A suitablegenerator is available as model number GEN11, from Ethicon Endo-Surgery,Inc., Cincinnati, Ohio.

The ultrasonic transducer 116 may convert the electrical signal from theultrasonic signal generator 120 into mechanical energy that results inprimarily a standing acoustic wave of longitudinal vibratory motion ofthe ultrasonic transducer 116 and the blade 10 portion of the endeffector assembly 126 at ultrasonic frequencies.

In various instances, the energy generated in the blade 10 can beemployed to cut and/or coagulate tissue. In one embodiment, vibrating athigh frequencies (e.g., 55,500 times per second), the ultrasonic blade10 may denature protein in the tissue to form a sticky coagulum.

Although the majority of the drawings depict a multiple end effectorassembly 126 for use in connection with laparoscopic surgicalprocedures, the ultrasonic surgical instrument 110 may be employed inmore traditional open surgical procedures and in other embodiments, maybe configured for use in endoscopic procedures.

In various embodiments, the generator 20 comprises several functionalelements, such as modules and/or blocks. Different functional elementsor modules may be configured for driving different kinds of surgicaldevices. For example, an ultrasonic generator module 121 may drive anultrasonic device, such as the ultrasonic surgical instrument 110. Insome example embodiments, the generator 120 also comprises anelectrosurgery/RF generator module 123 for driving an electrosurgicaldevice. In the example embodiment illustrated in FIG. 1, the generator120 includes a control system 125. When activated by the control system125, the generator 120 may provide energy to drive the blade 10 of thesurgical instrument 110.

Referring to FIG. 32, the elongated shaft assembly 114 comprises aproximal end portion 150 adapted to mechanically engage the handleassembly 112 and the distal rotation assembly 113, and a distal endportion 152 adapted to mechanically engage the end effector assembly126. The elongated shaft assembly 114 comprises an outer tubular sheath156 and a reciprocating tubular actuating member 158 located within theouter tubular sheath 156 that can actuate in the proximal direction 160a and the distal direction 160 b, as illustrated in FIG. 23.

The proximal end of the tubular reciprocating tubular actuating member158 is mechanically engaged to the trigger 132 of the handle assembly112 to move in either direction 60A or 60B in response to the actuationand/or release of the trigger 132. The pivotably moveable trigger 132may generate reciprocating motion along the longitudinal axis “T.” Suchmotion may be used, for example, to actuate an end effector 118 of theend effector assembly 126.

The distal end of the tubular reciprocating tubular actuating member 158is mechanically engaged to the end effector 118 (FIG. 32). In theillustrated embodiment, the distal end of the tubular reciprocatingtubular actuating member 158 is mechanically engaged to a clamp member164, which is pivotable about a pivot point 170, to open and close theclamp member 164 in response to the actuation and/or release of thetrigger 132. For example, in the illustrated embodiment, the clampmember 164 is movable in direction 162A from an open position to aclosed position about a pivot point 170 when the trigger 132 is squeezedtoward the handle 133. The clamp member 164 is movable in direction 1628from a closed position to an open position about the pivot point 170when the trigger 132 is released.

In the closed position, tissue such as, for example, a blood vessel maybe captured between the tissue-treating surface 20 of the blade 10 and atissue grasping feature 163 of the clamp member 164 of the end effector18. Pressure exerted on the captured tissue by the tissue-treatingsurface 20 may collapse the blood vessel and allow the coagulumresulting from application of the ultrasonic energy to form a hemostaticseal. A surgeon can control the cutting speed and coagulation by theforce applied to the tissue by the end effector 18, the time over whichthe force is applied and the selected excursion level of the endeffector 18.

The entire disclosures of:

U.S. patent application Ser. No. 14/448,430, titled ACTUATION MECHANISMSAND LOAD ADJUSTMENT ASSEMBLIES FOR SURGICAL INSTRUMENTS, filed Jul. 31,2014; and

U.S. Patent Publication No. 2014/0005704 A1, titled ULTRASONIC SURGICALINSTRUMENTS WITH DISTALLY POSITIONED JAW ASSEMBLIES, filed Jun. 29,2012, are hereby incorporated by reference herein.

EXAMPLES Example 1

A surgical instrument, comprising an ultrasonic transducer, anultrasonic transmission waveguide extending from the ultrasonictransducer, and an ultrasonic blade acoustically coupled to theultrasonic transmission waveguide. The ultrasonic blade comprises a baseand a curved body extending distally from the base. The curved bodycomprises, one, a tissue-treating surface extending on a first side ofthe curved body and, two, a curved edge extending on a second side ofthe curved body opposite the first side. The curved edge comprises aproximal end and a distal end, wherein the proximal end is offset fromthe distal end in a first direction, wherein the proximal end is offsetfrom the distal end in a second direction, and wherein the firstdirection is perpendicular to the second direction.

Example 2

The surgical instrument of Example 1, further comprising a blunt tip,wherein the blunt tip extends laterally beyond the base.

Example 3

The surgical instrument of Example 2, wherein the tissue-treatingsurface is tapered toward a distal end proximal to the blunt tip.

Example 4

The surgical instrument of Examples 1, 2, or 3, further comprising aclamp member movable relative to the tissue-treating surface to capturetissue therebetween.

Example 5

The surgical instrument of Examples 1, 2, 3, or 4 further comprising afirst acoustic balancing feature intersecting the tissue-treatingsurface.

Example 6

The surgical instrument of Example 5, further comprising second andthird acoustic balancing features intersecting at the proximal end ofthe cutting edge.

Example 7

A surgical instrument, comprising an ultrasonic transducer, anultrasonic transmission waveguide extending from the ultrasonictransducer, and an ultrasonic blade acoustically coupled to theultrasonic transmission waveguide. The ultrasonic blade comprises a baseand a curved body extending distally from the base. The curved bodycomprises a tissue-treating surface, a cutting edge, wherein thetissue-treating surface and the cutting edge are on opposite sides ofthe curved body, a blunt tip extending laterally beyond the base, aheight gradually tapered toward the blunt tip, and a width graduallytapered toward the blunt tip.

Example 8

The surgical instrument of Example 7, further comprising a clamp membermovable relative to the tissue-treating surface to capture tissuetherebetween.

Example 9

The surgical instrument of Examples 7 or 8, wherein the tissue-treatingsurface is tapered toward a distal end proximal to the blunt tip.

Example 10

The surgical instrument of Examples 7, 8, or 9, further comprising afirst acoustic balancing feature intersecting the tissue-treatingsurface.

Example 11

The surgical instrument of Example 10, further comprising second andthird acoustic balancing features intersecting at a proximal end of thecutting edge.

Example 12

A surgical instrument, comprising an ultrasonic transducer, anultrasonic transmission waveguide extending from the ultrasonictransducer, and an ultrasonic blade acoustically coupled to theultrasonic transmission waveguide. The ultrasonic blade comprises a baseand a curved portion extending distally from the base. The curvedportion comprises a first face, comprising a tissue-treating surface, afirst side wall intersecting the tissue-treating surface, and a secondside wall intersecting the tissue-treating surface. The curved portionfurther comprises a second face, wherein the first face and the secondface are on opposite sides of the curved portion, and wherein the secondface comprises a first intermediate wall intersecting the first sidewall, a second intermediate wall intersecting the second side wall, anda cutting edge extending distally along a length of the curved portion.The second face further comprises a first tissue cutting surface and asecond tissue cutting surface, wherein the first tissue cutting surfaceintersects the second tissue cutting surface at the cutting edge.

Example 13

The surgical instrument of Example 12, further comprising a blunt tip,wherein the blunt tip extends laterally beyond the base.

Example 14

The surgical instrument of Example 13, wherein the tissue-treatingsurface is tapered toward a distal end proximal to the blunt tip.

Example 15

The surgical instrument of Examples 12, 13, or 14, further comprising aclamp member movable relative to the tissue-treating surface to capturetissue therebetween.

Example 16

The surgical instrument of Examples 12, 13, 14, or 15, furthercomprising a first acoustic balancing feature intersecting thetissue-treating surface.

Example 17

The surgical instrument of Examples 12, 13, 14, 15, or 16, furthercomprising a second acoustic balancing feature extending proximally fromthe second tissue cutting surface.

Example 18

The surgical instrument of Example 17, further comprising a thirdacoustic balancing feature extending proximally from the first tissuecutting surface.

Example 19

The surgical instrument of Example 18, further comprising a fourthacoustic balancing feature, wherein the second acoustic balancingfeature defines a first peak, wherein the third acoustic balancingfeature defines a second peak, and wherein the fourth acoustic balancingfeature extends proximally from the first and second peaks.

Example 20

The surgical instrument of Examples 12, 13, 14, 15, 16, 17, 18, or 19,wherein the first and second tissue cutting surfaces define an angletherebetween, wherein the angle is selected from a range of about 85° toabout 120°.

Although the various embodiments of the devices have been describedherein in connection with certain disclosed embodiments, manymodifications and variations to those embodiments may be implemented.Also, where materials are disclosed for certain components, othermaterials may be used. Furthermore, according to various embodiments, asingle component may be replaced by multiple components, and multiplecomponents may be replaced by a single component, to perform a givenfunction or functions. The foregoing description and following claimsare intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

By way of example only, aspects described herein may be processed beforesurgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device also may be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, plasma peroxide, or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical instrument, comprising: an ultrasonictransducer; an ultrasonic transmission waveguide extending from theultrasonic transducer; and an ultrasonic blade acoustically coupled tothe ultrasonic transmission waveguide, wherein the ultrasonic bladecomprises: a base, wherein a longitudinal axis extends parallel throughthe base; and a curved body extending distally from the base, whereinthe curved body comprises: a proximal end positioned at the base; adistal end; a tissue-treating surface extending on a first side of thecurved body; a curved edge extending on a second side of the curved bodyopposite the first side, the curved edge curving away from thelongitudinal axis at a first point between the proximal end and thedistal end, and then curving back toward the longitudinal axis at asecond point between the first point and the distal end; and a balancingfeature positioned between the proximal end and a midway point to thedistal end, the balancing feature comprising a contour line that createsan asymmetry in the curved body; wherein the distal end is offset fromthe longitudinal axis in a first direction, wherein the distal end isoffset from the longitudinal axis in a second direction, and wherein thefirst direction is perpendicular to the second direction.
 2. Thesurgical instrument of claim 1, further comprising a blunt tip, whereinthe blunt tip extends laterally beyond the base, and wherein the blunttip is offset from the longitudinal axis in the first direction and inthe second direction.
 3. The surgical instrument of claim 2, wherein thetissue-treating surface is tapered toward a distal end proximal to theblunt tip.
 4. The surgical instrument of claim 1, further comprising aclamp member movable relative to the tissue-treating surface to capturetissue therebetween.
 5. The surgical instrument of claim 1, wherein thecontour line of the balancing feature is curved concavely and intersectsthe tissue-treating surface, and the tissue-treating surface is curvedconvexly.
 6. The surgical instrument of claim 5, wherein the balancingfeature is a first acoustic balancing feature, and the surgicalinstrument further comprises second and third acoustic balancingfeatures intersecting at the proximal end.
 7. A surgical instrument,comprising: an ultrasonic transducer; an ultrasonic transmissionwaveguide extending from the ultrasonic transducer; and an ultrasonicblade acoustically coupled to the ultrasonic transmission waveguide,wherein the ultrasonic blade comprises: a base, wherein a longitudinalaxis extends parallel through the base; and a curved body extendingdistally from the base, wherein the curved body comprises: atissue-treating surface; a cutting edge, wherein the tissue-treatingsurface and the cutting edge are on opposite sides of the curved body,and wherein the cutting edge comprises: a proximal end; a distal end,wherein the cutting edge extends between the proximal end and the distalend along a curved path, the curved path curving away from thelongitudinal axis at a first point between the proximal end and thedistal end, and then curving back toward the longitudinal axis at asecond point between the first point and the distal end; and a balancingfeature positioned between the proximal end and a midway point to thedistal end, the balancing feature comprising a contour line that createsan asymmetry in the curved body; wherein the curved path is offset fromthe longitudinal axis in two different directions; a blunt tip extendinglaterally beyond the base, wherein the blunt tip is offset from thelongitudinal axis in a first direction and a second direction, whereinthe first direction is perpendicular to the second direction; a heightgradually tapered toward the blunt tip; and a width gradually taperedtoward the blunt tip.
 8. The surgical instrument of claim 7, furthercomprising a clamp member movable relative to the tissue-treatingsurface to capture tissue therebetween.
 9. The surgical instrument ofclaim 7, wherein the tissue-treating surface is tapered toward a distalend of the tissue treating surface, wherein the distal end of the tissuetreating surface is proximal to the blunt tip.
 10. The surgicalinstrument of claim 7, wherein the contour line of the balancing featureis curved concavely and intersects the tissue-treating surface, and thetissue-treating surface is curved convexly.
 11. The surgical instrumentof claim 10, wherein the balancing feature is a first acoustic balancingfeature, and the surgical instrument further comprises second and thirdacoustic balancing features intersecting at the proximal end.
 12. Asurgical instrument, comprising: an ultrasonic transducer; an ultrasonictransmission waveguide extending from the ultrasonic transducer; and anultrasonic blade acoustically coupled to the ultrasonic transmissionwaveguide, wherein the ultrasonic blade comprises: a base, wherein alongitudinal axis extends parallel through the base; and a curvedportion extending distally from the base, wherein the curved portioncomprises: a first face, comprising: a proximal end, wherein thelongitudinal axis extends through the proximal end; a distal end,wherein the distal end is offset from the longitudinal axis in a firstdirection, wherein the distal end is offset from the longitudinal axisin a second direction, and wherein the first direction is perpendicularto the second direction; a tissue-treating surface; a first side wallintersecting the tissue-treating surface; a second side wallintersecting the tissue-treating surface; and a balancing featurepositioned between the proximal end and a midway point to the distalend, the balancing feature comprising a contour line that creates anasymmetry in the curved portion; and a second face, wherein the firstface and the second face are on opposite sides of the curved portion,and wherein the second face comprises: a first intermediate wallintersecting the first side wall; a second intermediate wallintersecting the second side wall; a cutting edge extending distallyalong a length of the curved portion, the cutting edge curving away fromthe longitudinal axis at a first point between the base and a distal endof the curved portion, and then curving back toward the longitudinalaxis at a second point between the first point and the distal end of thecurved portion; a first tissue cutting surface; and a second tissuecutting surface, wherein the first tissue cutting surface intersects thesecond tissue cutting surface at the cutting edge.
 13. The surgicalinstrument of claim 12, further comprising a blunt tip, wherein theblunt tip extends laterally beyond the base, and wherein the blunt tipis offset from the longitudinal axis in the first direction and in thesecond direction.
 14. The surgical instrument of claim 13, wherein thetissue-treating surface is tapered toward a distal end proximal to theblunt tip.
 15. The surgical instrument of claim 12, further comprising aclamp member movable relative to the tissue-treating surface to capturetissue therebetween.
 16. The surgical instrument of claim 12, whereinthe contour line of the balancing feature is curved concavely andintersects the tissue-treating surface, and the tissue-treating surfaceis curved convexly.
 17. The surgical instrument of claim 16, wherein thebalancing feature is a first acoustic balancing feature, and thesurgical instrument further comprises a second acoustic balancingfeature extending proximally from the second tissue cutting surface. 18.The surgical instrument of claim 17, further comprising a third acousticbalancing feature extending proximally from the first tissue cuttingsurface.
 19. The surgical instrument of claim 18, further comprising afourth acoustic balancing feature, wherein the second acoustic balancingfeature defines a first peak, wherein the third acoustic balancingfeature defines a second peak, and wherein the fourth acoustic balancingfeature extends proximally from the first and second peaks.
 20. Thesurgical instrument of claim 12, wherein the first and second tissuecutting surfaces define an angle therebetween, wherein the angle isselected from a range of about 85° to about 120°.